Electrolytic hydrogen generating system

ABSTRACT

A hydrogen generating system includes a housing defining an interior chamber, an electrolyte solution contained within the interior chamber of the housing, and an electrode plate assembly disposed in the interior chamber of the housing and at least in part submerged in the electrolyte solution. The electrode plate assembly comprises a cathode plate, an anode plate separate from the cathode plate and disposed in spaced relationship therewith, and at least one neutral plate separate from both the anode plate and the cathode plate and disposed therebetween in spaced relationship with the anode plate and the cathode plate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application No. 61/115,463 filed on Nov. 17, 2008 and No. 61/117,481 filed on Nov. 24, 2008, respectively, both of which are hereby incorporated by reference in their entirety.

BACKGROUND

The use of hydrogen and oxygen gas to supplement the conventional fuel in an internal combustion engine in order to increase the efficiency of the engine is known. For example, electrolytic hydrogen generating systems are known to produce hydrogen and oxygen gases for use as fuel additives. However, a satisfactory hydrogen generating system that efficiently uses the power supplied to the system and generates a sufficient supply of gases at acceptable temperatures does not yet exist.

BRIEF DESCRIPTION

In one aspect, a hydrogen generating system comprises a housing defining an interior chamber, an electrolyte solution contained within the interior chamber of the housing, and an electrode plate assembly disposed in the interior chamber of the housing and at least in part submerged in the electrolyte solution. The electrode plate assembly comprises a cathode plate, an anode plate separate from the cathode plate and disposed in spaced relationship therewith, and at least one neutral plate separate from both the anode plate and the cathode plate and disposed therebetween in spaced relationship with the anode plate and the cathode plate. A power source is in electrical communication with the electrode plate assembly.

In another aspect, a hydrogen generating system comprises a housing defining an interior chamber, an electrolyte solution contained within the interior chamber of the housing, and an electrode plate assembly disposed in the interior chamber of the housing and at least in part submerged in the electrolyte solution. The electrode plate assembly comprises a plurality of electrode plates. At least one electrode plate has opposite faces exposed to the electrolyte solution. A cathode plate has opposite faces exposed to the electrolyte solution. The at least one electrode plate has a length, a height, a thickness and a plurality of surface features on at least one of the opposite faces such that the at least one electrode plate has a surface area that is greater than a surface area of a hypothetical electrode plate having the same length, height and thickness as the at least one electrode plate and free from said surface features. A power source is in electrical communication with the electrode plate assembly.

In still another aspect, a hydrogen generating system comprises a housing defining an interior chamber, an electrolyte solution contained within the interior chamber of the housing, and an electrode plate assembly disposed in the interior chamber of the housing and submerged at least in part in the electrolyte solution. The electrode plate assembly comprises a plurality of electrode plates, at least one electrode plate having opposite faces exposed to the electrolyte solution, and a cathode plate having opposite faces exposed to the electrolyte solution. The at least one electrode plate has a length, a height, a thickness and a plurality of holes extending through the thickness of the electrode plate from one of said opposite faces to the other one of said opposite faces. A power source is in electrical communication with the electrode plate assembly.

An electrode plate assembly for a hydrogen generator comprises a plurality of electrode plates and at least one electrically non-conductive bracket engaging the plates. The bracket comprises a bridge and a plurality of spacers extending from the bridge in spaced relationship with each other. The spacing between the spacers is adapted for receiving a respective one of the electrode plates therebetween such that the plates are maintained by the spacers in uniform spaced relationship with each other.

Various refinements exist of the features noted in relation to the above-mentioned aspects. Further features may also be incorporated in the above-mentioned aspects as well. These refinements and additional features may exist individually or in any combination. For instance, various features discussed below in relation to any of the illustrated embodiments may be incorporated into any of the above-described aspects, alone or in any combination.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective of a hydrogen generating system of one suitable embodiment;

FIG. 2 is a perspective of a frame of the device of FIG. 1;

FIG. 3 is an exploded view of the frame;

FIG. 4 is a front view of a reservoir of the system of FIG. 1;

FIG. 5 is an exploded cross-section taken in the plane of line 5-5 of FIG. 4;

FIG. 6 is an exploded view of a housing of the system of FIG. 1;

FIG. 7 is a top plan view of the housing;

FIG. 8 is a cross-section taken in the plane of lines 8-8 of FIG. 7;

FIG. 9 is a bottom perspective of a lid of the housing of FIG. 1;

FIG. 10 is a bottom plan view of the lid of FIG. 9;

FIG. 11 is a front elevation of the lid;

FIG. 12 is a front elevation of the housing and showing a heater of the system;

FIG. 13 is an exploded view of an electrode plate assembly of the housing of FIG. 6;

FIGS. 14A-14D are perspectives of plates of the electrode plate assembly;

FIGS. 15A-15B are perspectives of connectors of the electrode plate assembly;

FIGS. 16A-16C are perspectives of a retention bracket of the electrode plate assembly;

FIG. 17 is a perspective of a plate assembly of a second embodiment;

FIG. 18 is a block diagram of a vehicle including a hydrogen generating system;

FIG. 19 is a block diagram of a hydrogen generating system including an example electronic controller;

FIGS. 20 and 21 are flow charts showing an operation of the electronic controller;

FIG. 22 is a flow chart showing an operation of the electronic controller dynamically adding or removing a quantity of active plates;

FIG. 23 is a schematic of another embodiment of an electrode plate assembly;

FIG. 24 is a graph showing how the electronic controller can determine which plate set is active;

FIG. 25 is a graph that illustrates gas production versus time;

FIG. 26 is a graph that illustrates temperature versus time;

FIG. 27 is a graph that illustrates amperage versus time;

FIG. 28 is a graph that illustrates efficiency versus time;

FIG. 29 is a graph that illustrates gas production versus temperature;

FIG. 30 is a perspective of a hydrogen generating system of another embodiment;

FIG. 31 is a front elevation of the system of FIG. 30 with a housing removed to show a plate assembly;

FIG. 32 is a cross-section taken in the plane of lines 33-33 of FIG. 30; and

FIG. 33 is a cross-section taken in the plane of lines 33-33 of FIG. 30.

DETAILED DESCRIPTION

Referring now to the drawings and particularly to FIG. 1, a fuel emission device or hydrogen generating system of one suitable embodiment is generally designated 11. The hydrogen generating system 11 generally comprises a housing 13 and a frame 15 for supporting the housing 13. In this embodiment, the hydrogen generating system 11, and in particular the housing 13 and the frame 15, are adapted for mounting on a vehicle 19 (see FIG. 18), such as a diesel tractor of a tractor-trailer combination, and operably connected to an internal combustion engine 21 (see FIG. 18). A power source of the hydrogen generating system 11 may be, for example a 12 volt or a 24 volt source, though the hydrogen generating system 11 may be adapted to multiple voltage sources. This embodiment also includes a reservoir 25 containing maintenance solution 27, as shown in FIG. 5, for facilitating continued operation of the hydrogen generating system 11. The reservoir 25 may, however, be omitted within the scope of this disclosure.

As shown in FIGS. 2 and 3, the frame 15 includes a floor 31 supporting the housing 13, side walls 33, and a back wall 35 (each of which are broadly referred to as “frame members”) such that the housing 13 is surrounded on three sides. In other embodiments, the back wall 35 may be omitted. Upper ends of the side walls 33 have outwardly extending flanges 37. L-shaped brackets 39 are sized to engage the flanges 37 and to secure the housing 13 on the frame 15. The frame members are suitably secured by fasteners 41 (e.g., bolts and nuts), but may be secured in other ways, and may also be made as a one-piece unitary frame.

The frame 15 also includes an upright panel 43 secured to the back wall 35. The upright panel 43 has side flanges 45 along both vertical edges that extend forward around the side walls 33. The side flanges 45 add strength to the upright panel 43. The frame 15 is suitably made of steel, though other materials may be used.

Referring to FIGS. 4-5, the reservoir 25 includes a top 51, a bottom 53, a front wall 55, a right wall 56, a left wall 57, and a back wall 58. The back wall 58 is generally flat and includes flanges 61 having holes 63 therein for receiving fasteners (not shown) therethrough. The fasteners secure the reservoir 25 to the upright panel 43 of the frame 15.

The reservoir 25 includes a relatively large opening 64 formed in a neck 65 at the top 51 of the reservoir 25. The opening 64 is closed by a removable cap 67 that is suitably secured to the neck 65 (e.g., releasably secured by threads, not shown). The reservoir 25 also includes an outlet port 69 extending from the bottom 53 of the reservoir 25. A suitable conduit such as a tube 71 (see FIG. 1) connects the outlet port 69 to the housing 13.

Referring to FIGS. 6-8, the housing 13 defines an interior chamber 75 containing an electrolyte solution 77, an electrode plate assembly 79, a gasket 81 and a lid 83. The electrode plate assembly 79 is generally received in the chamber 75, and at least partially submersed, and more suitably fully submersed in the electrolyte solution 77. The gasket 81 of this embodiment is an O-ring made of a material capable of withstanding high temperatures, such as 250° F. and is generally adapted to facilitate sealing the housing 13. The lid 83 of this embodiment is also generally rectangular and is configured to cover the chamber 75. The gasket 81 and the lid 83 are adapted to seal the housing 13.

Referring to FIGS. 9-11, the lid 83 includes a set of channels 87 formed in an inner surface 89 of the lid 83 for channeling gas generated within the chamber 75 to a dome portion (e.g., collector 91) of the lid 83. In this embodiment, the channels 87 are V-shaped in cross-section and an end of each of the channels 87 are adjacent to an end of the lid 83. Each of the channels 87 extend generally from the end adjacent to the lid 83 to the collector 91. An outlet 93 is disposed at an apex of the collector 91. A suitable delivery system, such as conduit 95 (see FIG. 1) connects the outlet 93 to the engine 21 of the vehicle 19 (see FIG. 18). The lid 83 has holes 96 around the periphery 97 for receiving fasteners that secure the lid 83 to the housing 13. The lid 83 has a square recess 99 for receiving a temperature sensor 101 (e.g., a thermistor) to sense the temperature of the hydrogen generating system 11. The sensor 101 may be disposed inside or outside the chamber 75, and may be disposed anywhere on the housing 13.

The delivery system may also include a condenser 100 disposed along the conduit 95 for inhibiting water vapor from entering the engine 21. The condenser may suitably be a bubbler-type condenser, though other types are contemplated.

Referring to FIGS. 6 and 12, the housing 13 has a generally rectangular opening for receiving the electrode plate assembly 79 when the lid 83 is removed. The housing 13 also has four generally upright sides 103 and a bottom 105. Ribs 106 on the sides 103 strengthen the housing 13. The housing 13 includes a flange 107 along an upper edge that mates with the lid 83. Fasteners 98 extend through the lid 83 and the flange 107 of the housing 13.

The housing 13 of this embodiment is of unitary, one-piece construction. The housing 13 is made of a crack and corrosion resistant material. Also, the material may be non-insulating so that thermal energy (e.g., heat) can be more easily transmitted through the housing 13. One suitable material for the housing 13 is high-density polyethylene which can be molded to form the housing 13. Other materials may be used without departing from the scope of this disclosure.

As shown in FIG. 12, an exterior of the bottom 105 of the housing 13 includes a central recess 109. The recess 109 spaces a portion of the housing 13 above the frame 15, and is suitably configured to accommodate a heater 110 in abutting, thermal communication with the exterior of the bottom 105 (or generally the underside) of the housing 13. The heater 110 may be any suitable type of heater, including for example a radiant heater. The heater 110 may be used to warm the housing 13 and the solution 77 therein to an operating temperature more quickly.

Referring to FIG. 13, the electrode plate assembly 79 generally includes electrode plates, suitable brackets 121 (e.g., retention brackets), and connection posts 141. The electrode plates in this embodiment may be generally characterized as one of a neutral plate 125N (FIG. 14A), an anode plate 125A (FIG. 14B), or a cathode plate 125C (FIG. 14C). Each electrode plate is generally rectangular and may include notches 129 along each edge. For example, as shown in FIG. 14A, the neutral plate 125N includes one notch 129 on a top edge 136, one notch 129 on each side edge 137, and two notches 129 along a bottom edge 138 to accommodate retention brackets 121. Each electrode plate may have fastener holes 131 in a periphery of each electrode plate for receiving fasteners 122 therethrough for use in securing the retention brackets 121 on the electrode plate assembly 79.

One or more of the electrode plates may include surface features, such as openings or holes, that are sized and shaped to increase a surface area and “active sites” of the one or more electrode plates. As shown in FIG. 14A, suitable surface features include a plurality of holes in the form of slots 133 formed in a central section of the neutral plate 125N. Other shapes of openings are contemplated within the scope of the disclosure. The slots 133 provide an increase in surface area of at least about 0.3%, and in some embodiments at least about 0.5%, when compared to a hypothetical plate of the same dimensions but without surface features. A ratio of surface area of each electrode plate having surface features as compared to the hypothetical electrode plate without such features is at least 1.03, and in some embodiments at least about 1.05.

In one example (further described below in the Example surface area section) each electrode plate is 0.40005×0.17780×0.00160 meters (16 gauge) and includes 200 slots 133. Each slot 133 has a radius of 0.00117 meters. This configuration results in an increase in surface area of about 0.5% (with a ratio of 1.005) when the surface area of an electrode plate includes openings as compared to the hypothetical plate without such openings. In this embodiment, the cathode plate 125C and the anode plate 124A do not include slots 133, but only holes 131 for receiving the fasteners 122 therethrough. However, other embodiments have small slots 133 in the anode plate 125A and/or the cathode plate 125C. The electrode plates may have other surface features for increasing surface area (e.g., additional surfaces, slits, holes, bumps, projections, or a rough or an abraded surface). For example, the plate 125D of FIG. 14D includes projections 134 extending outward from a surface or face of the plate 125D, and dimples or impressions 135 extending inward into the surface.

In one suitable plate assembly shown in FIG. 13, cathode plates 125C (first and second cathode plates) are disposed at each end of the electrode plate assembly 79 so that the plates are in spaced apart relationship. An anode plate 125A is separate from the cathode plates 125C and disposed in a center of the electrode plate assembly 79 intermediate the cathode plates in spaced apart relationship therewith. A plurality of neutral plates 125N are disposed between each cathode plate 125C and the anode plate 125A, each neutral plate in spaced relationship with the anode plate and the cathode plates.

The cathode plates 125C and the anode plate 125A may be swapped such that one anode plate 125A is at each end of the electrode plate assembly 79 and one cathode plate 125C is in the center of the electrode plate assembly 79. The number of neutral plates 125N may also vary. In embodiments, for example, there may be 18 neutral plates 125N, 16 neutral plates 125N, 14 neutral plates 125N, 12 neutral plates 125N, 10 neutral plates 125N, or 8 neutral plates 125N. In the latter embodiment (8 neutral plates 125N), there are a total of 11 electrode plates (8 neutral plates 125N, one anode plate 125A, and two cathode plates or end plates 125C).

One advantage of using more electrode plates is that using more electrode plates enables the hydrogen generating system 11 to operate at a lower temperature. For example, in embodiments where the anode plate 125A is in the center of the electrode plate assembly 79, the number of neutral plates 125N on either side of the anode plate 125A may be equal. However, other numbers and configurations of the electrode plates are contemplated.

Two cathode plates 125C may be electrically connected by suitable connectors, such as by a U-shaped connector 139 shown in FIG. 15A or by other suitable connector(s). A post 141 extends upward from the U-shaped connector 139. In this embodiment, the post 141 is suitably a “clench” or threaded fastener that is joined to the U-shaped connector 139 by a nut 143. The post 141 may be joined to the U-shaped connector 139 by a separate fastener, by welding, or the like. The post 141 may also be formed as one-piece with the U-shaped connector 139. Likewise, the U-shaped connector 139 is suitably joined to the cathode plates 125C by a fastener, but may be joined in other suitable ways. For example, the U-shaped connector 139 and the post 141 may also both be formed as one-piece with one or both of the cathode plates 125C.

An L-shaped connector 147 (FIG. 15B) has the post 141 extending upward from a main surface of the L-shaped connector 147. The L-shaped connector 147 is suitably joined to the anode plate 125A at a top edge of the anode plate 125A by threads as described above. Like the U-shaped connector 139 of FIG. 15A, the post 141 may be made as one-piece with the L-shaped connector 147 and the anode plate 125A. The posts 141 are suitably connected to the power source by wires (not shown).

In the embodiment shown in FIG. 13, the electrode plate assembly 79 may alternatively be referred to as a “cell.” In further embodiments, more than one electrode plate assembly 79, or cell, may be used. For example, a second electrode plate assembly, or cell, may be added to the electrode plate assembly 79, described above, and more suitably a non-conductive barrier may be disposed between each of the electrode plate assemblies.

Each electrode plate is made of a suitable material that is resistant to reactivity with the solution 77 or amperage applied. In one embodiment, the electrode plates are made of a 316L stainless steel. The material of an electrode plate is chosen to have an appropriate resistance. Each electrode plate should be sufficiently thick to reduce electrical resistance and to inhibit significant flexing of the electrode plates. In some embodiments, each electrode plate is between 16 gauge and 20 gauge, and in one embodiment each electrode plate is 20 gauge. Note that a resistance of a wire (and by analogy an electrode plate) is generally affected by four factors: (1) material (for example, gold and silver have relatively low resistance), (2) a thickness of the wire or the electrode plate, (3) a temperature of the wire or the electrode plate, and (4) a length of the wire (but a length of an electrode plate is not an applicable factor). The thicker an electrode plate, the more space exists for a current to flow. As an electrode plate warms up, there is more energy therein and a resistance to a current and an electron flow decreases.

Referring to FIGS. 16A-C, each retention bracket 121 is generally U-shaped. Each bracket 121 is generally “combed”, meaning that each bracket 121 includes a bridge 148 and a plurality of spacers 149 (or teeth) spaced apart such that one electrode plate fits between two adjacent spacers 149. Spacing between spacers 149 is uniform so that a spacing between each electrode plate is equal. In one embodiment, for example, the spacing between each electrode plate is suitably between about 2.0 mm and about 6.5 mm. Fasteners (for example, the fasteners 122) extend through the brackets 121 and through the electrode plates to secure the stack (e.g., the electrode plate assembly), together. Each bracket is suitably made of an electrically non-conductive material.

Referring to FIG. 17, in this embodiment, there are 12 interleaved electrode plates 151. The electrode plates 151 may be formed as described above (e.g., of low carbon stainless steel). Each electrode plate 151 is configured for an electrical connection point 153 at one end of each electrode plate 151, for a total of 12 connection points. The plates are interleaved such that connection points of adjacent plates 151 are opposite one another. A first set of electrical connections 153 are attached (e.g., by jumper wires) to connector blocks 156, with a corresponding second set of electrical connections 153 being attached to a respective wire harnesses (not shown) and connected to an electrical controller 202 (see FIG. 19). Generally, the controller 202 switches an electrical current to various combinations of electrode plate sets to develop a best use of current in the hydrogen generating system 11, such as by the method described below.

Generating system 11′ of another embodiment shown in FIG. 23 and FIGS. 30-32 is similar to the system 11 of FIGS. 1-12. The positioning of the electrode plates in generating system 11′ is shown schematically in FIG. 23 and described in more detail in the Example System below. In this embodiment, plate assembly 502 includes 22 electrode plates (six anode plates 510, 512, 514, 516, 518, 520, one cathode plate 508, and 15 neutral plates 524). Alternatively, the anode plates may instead be cathode plates, and the cathode plate may be an anode plate. Also, if not energized, the anode plates 510, 512, 514, 516, 518, 520 serve as neutral plates. As shown, the cathode plate 508 includes a post 509 that extends through the lid 83, and each anode plate 125A includes a similar post 511 that extends through the lid 83 at an opposite end of the lid 83.

The brackets 121′ of this embodiment include spacers 122′ that extend upward about 1.5 inches. The brackets 121 are sized such that there is about 0.25 inches clearance between a bottom of the electrode plates and the housing 13. The brackets 121 may also be beveled to provide clearance of the electrode plates relative to the housing 13.

Referring to FIG. 32, a float mechanism 124 extends from a port in the lid 83. The float mechanism 124 serves to ensure that the solution 77′ is at a level above a top of the electrode plate assembly 502. The float mechanism 124 is suitably a conventional float 126 similar to a type used in a home toilet tank. The mechanism 124 is in fluid communication with the solution 77′ in the chamber 75′ and with the reservoir 25 via tube 71′. When the level of the solution 77′ begins to fall, the float 126 pivots downward, opening a valve that allows maintenance solution (e.g., solution 27) from the reservoir 25 to enter the chamber 75′. As the level of the solution 77′ rises, the float 126 moves upward and closes the valve. Note that the reservoir 25 is suitably disposed above the housing 13′ for gravity flow of the maintenance solution to the chamber.

One advantage of some embodiments of this disclosure is that each electrode plate can be monitored to control an amperage level generated. As described in detail below, power can be channeled to each electrode plate as needed to increase hydrogen production for a given amperage. This can increase the generation of hydrogen and oxygen available at start-up and significantly reduce a usual warm-up period required to get the hydrogen generating system 11 to full production at optimum temperature.

Starter and Maintenance Solutions:

The housing 13 or 13′ has sufficient fluid (e.g., electrolyte solution 77) therein so that the electrode plates are submersed in the fluid. Opposite faces (both faces) of the electrode plates (any of the plates described herein) are exposed to the electrolyte solution. Also, the surface features as described herein are exposed to the solution. The fluid of one embodiment is a solution having 20-320 mL of 2.14 molar potassium hydroxide diluted to 11.353 liters. In this embodiment, the electrolyte suitably contains color and buffers.

In the above embodiment, 200 mL of 2.14 molar solution is added to the chamber 75 or 75′ and diluted with distilled water to a capacity of the chamber, for example 11.353 liters. A concentration of electrolyte facilitates the electrical current through the aqueous solution.

The reservoir 25 holds a maintenance solution (e.g., solution 27). In one embodiment, the maintenance solution includes two buffer solutions and distilled water, though it is contemplated to use only distilled water. The first buffer is alkaline, and includes boric acid (H₂B₄O₇) and Sodium hydroxide, N_(a)OH. The solution has a pH of about 12.7. In one embodiment, there is between 25 grams and 35 grams of boric acid and between about 9 grams and 15 grams of sodium hydroxide, in another embodiment between about 30 and 32 grams of boric acid and between 11 grams and 13 grams of sodium hydroxide, and in one embodiment about 31.4 grams of boric acid and about 12 grams of sodium hydroxide. In one embodiment, the solution is made by dissolving the boric acid and sodium hydroxide in 1 liter of distilled water. This yields 0.1 M concentrations of each species. Then 10 mL of the solution is added to 3.7843 liters of distilled water. A suitable dye, such as bromothymol blue, may then be added.

The second buffer solution for the maintenance solution is also alkaline and includes dipotassium phosphate (K₂HPO₄) and tripotassium phosphate K₃PO₄. The solution has a pH in a range of 10-14, or in some embodiments between 11 and 13, and in some embodiments about 12.7. In one embodiment, there is between 10 grams and 20 grams of dipotassium phosphate and between about 9 grams and 15 grams of tripotassium phosphate, in another embodiment between about 30 grams and 32 grams of dipotassium phosphate and between 11 grams and 13 grams of tripotassium phosphate, and in one embodiment about 15.8 grams of dipotassium phosphate and about 19.6 grams of tripotassium phosphate. In one embodiment, the solution is made by dissolving the dipotassium phosphate and tripotassium phosphate in 1 liter of distilled water. This yields 0.1 M concentrations of each species. Then 10 mL of the solution is added to 3.7843 liters of distilled water. A suitable dye, such as bromothymol blue, may then be added.

Example System

Referring to FIG. 18, an exemplary block diagram of the vehicle 19 (e.g., a truck) including the hydrogen generating system 11 in communication with the engine 21 of the vehicle is shown. Note that system 11′ can be used instead. Embodiments of the disclosure enable the hydrogen generating system 11 to generate a sufficient amount hydrogen gas per minute (e.g., 6 liters of hydrogen gas per minute) at a very low temperature (e.g., 40° F.) immediately upon start-up. Further, embodiments of the present disclosure enable the hydrogen generating system to manage heat at high temperatures (e.g., 140-180° F.) while producing acceptable quantities of hydrogen gas (e.g., over 2 liters per minute).

Referring to FIG. 19, an exemplary block diagram of the hydrogen generating system 11 including an electronic controller 202 is shown. Embodiments of the disclosure enable the electronic controller 202 to monitor an actual amperage and an actual temperature of the hydrogen generating system 11. Further, the embodiments described herein enable the hydrogen generating system 11 to achieve increased amperage between electrode plates of a cell substantially immediately upon a start-up of the hydrogen generating system 11 by effectively omitting a quantity of electrode plates over which a voltage is applied.

The electronic controller 202 as described herein has one or more processors 204 or processing units, a memory area 206, and some form of computer readable media. By way of example and not limitation, computer readable media comprise computer storage media and communication media. Computer storage media include volatile and nonvolatile, removable and non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Communication media typically embody computer readable instructions, data structures, program modules, or other data in a modulated data signal such as a carrier wave or other transport mechanism and include any information delivery media. Combinations of any of the above are also included within the scope of computer readable media.

Although the processor(s) 204 is shown separate from the memory area 206, embodiments of the disclosure contemplate that the memory area 206 may be onboard the processor(s) 204 such as in some embedded systems. The processor(s) 204 executes computer-executable instructions for implementing aspects of the disclosure. For example, the processor(s) 204 is programmed with instructions such as illustrated in FIGS. 20-22. The computer-executable instructions may be organized into one or more computer-executable components or modules. Generally, program modules include, but are not limited to, routines, programs, objects, components, and data structures that perform particular tasks or implement particular abstract data types. Aspects of the present disclosure may be implemented with any number and organization of such components or modules. For example, aspects of the invention are not limited to the specific computer-executable instructions illustrated in the figures and described herein. Other embodiments of the invention may include different computer-executable instructions. Aspects of the disclosure may also be practiced in distributed computing environments where tasks are performed by remote processing devices that are linked through a communications network. The processor(s) 204 is transformed into a special purpose microprocessor by executing computer-executable instructions or by otherwise being programmed.

The electronic controller 202 may be in communication with a display device (not shown) separate from or physically coupled to the hydrogen generating system 11. The display device may be a capacitive touch screen display, or a non-capacitive display. User input functionality may also be provided in the display, where the display acts as a user input selection device such as in a touch screen. The display device may provide a user with information regarding the hydrogen generating system 11, such as, temperature, measured amperage, error messages, and the like.

In this embodiment, the hydrogen generating system 11 includes a temperature sensor (e.g., temperature sensor 101) configured to measure an actual temperature of the hydrogen generating system 11. The temperature sensor 101 may be disposed on the outside of the housing 13. Due to the thermal properties of the housing 13, a temperature drop across a wall of the housing 13 is minimal so that the sensed/measured temperature is relatively close to the temperature inside the housing 13. However, the temperature sensor 101 may alternatively be disposed inside the housing 13.

A time from a start-up to optimum operating temperature (e.g., about 140° F. to about 160° F.) of the hydrogen generating system 11 is a function of an amount of amperage generated by electrolysis. Therefore, as temperature increases, amperage increases, and an efficiency for producing hydrogen gas increases. An amperage sensor (not shown) may be used to measure an actual amperage of the hydrogen generating system 11. In a further embodiment, the hydrogen generating system 11 includes resistors configured to measure an actual amperage.

Referring next to FIG. 20, a flow chart showing an operation of the electronic controller 202 is shown. Upon a start-up of the hydrogen generating system 11, at 208 a target amperage (e.g., about 20 amps to about 30 amps) and a maximum threshold temperature (e.g., about 180° F.) is received. The target amperage and the maximum threshold temperature may be automatically set by a manufacturer and/or manually selected by a user via the display device.

To control amperage, the electronic controller 202 enables each electrode plate in the electrode plate assembly 79 to be individually monitored and controlled. At 210, a quantity of electrode plates less than a total quantity of the electrode plates in the electrode plate assembly 79 to apply a voltage to is selected. Choosing to apply a voltage across a selected quantity of electrode plates less than a total quantity of the electrode plates in the electrode plate assembly 79 can result in higher currents dissipating more power. This causes a faster rise in a temperature of an electrolyte between the electrode plates to which the voltage is applied (e.g., the active electrode plate set), thereby increasing production of hydrogen gas that is being produced by the active electrode plates. For example, as temperature increases, the electrolyte becomes more conductive, enabling an inclusion of additional electrode plates in the active electrode plate set and thus increasing the efficiency of hydrogen gas produced by the hydrogen generating system 11. Applying a voltage across a quantity of electrode plates less than a total quantity of electrode plates in the electrode plate assembly enables the hydrogen generating system to generate at least 2 liters of hydrogen gas per minute at a very low temperature (e.g., 40° F.) substantially immediately upon start-up. In one embodiment, only the electrode plates required to achieve the target amperage receive an applied voltage. The quantity of the plurality of electrode plates that receive the applied voltage may be based on at least one of the following: a temperature of an electrolytic solution, an amount of voltage applied, a distance between each of the plurality of electrode plates (e.g., about 3 mm), and a type and concentration of electrolytic solution used. This can increase generation of hydrogen and oxygen available at start-up and significantly reduce a warm-up period required to get the hydrogen generating system 11 to full production at optimum temperature, the process of which is described in detail below.

The electronic controller 202 provides a pulse of electricity at a particular voltage for a duty cycle of, for example, 4 ms (four milliseconds). The length of the duty cycle (i.e., 4 ms) is merely exemplary and is not intended to limit the scope of the present disclosure. One of ordinary skill in the art will appreciate that various lengths of time may be used, for example, 8 ms, 12 ms, and 14 ms may be used. A duty cycle may be limited by applying the pulse for a fraction of the duty cycle. For example, with a duty cycle of 4 ms, a pulse may be applied for only 3 ms of the 4 ms duty cycle, 2 ms of the 4 ms duty cycle, or even 1 ms of the 4 ms duty cycle. In further embodiments, the pulse applied during the 4 ms duty cycle can be divided even further, for example, to 1/16 or 1/32 of the 4 ms duty cycle.

After a voltage is applied to the selected quantity of plates, at 212, an actual amperage and an actual temperature of the hydrogen generating system 11 are measured. To compensate for an increased temperature as the process of electrolysis occurs, the electronic controller 202 can effectively lower the voltage applied to the selected number of the plurality of plates (e.g., by decreasing the time a pulse is applied in the duty cycle) to maintain the amperage at a desired level during operation. For example, at 214, the electronic controller 202 is configured to compare the actual amperage to an amperage threshold (e.g., 25 amps), compare the actual temperature to a maximum threshold temperature (e.g., 160° F.), and at 216, adjust at least one of a duty cycle and/or the applied voltage based on the comparisons in order to regulate the actual temperature and the actual amperage. For example, if it is determined that an actual amperage exceeds a maximum amperage threshold (e.g., 30 amps) and/or the actual temperature is greater than the optimal temperature, the duty cycle may be adjusted to enable an average of an actual amperage to substantially equal the target amperage. In contrast, if it is determined that the actual amperage is equal to or less than the maximum amperage threshold, and the actual temperature is less than or equal to the optimal temperature, at 218, the duty cycle may be increased. For example, a maximum voltage may be applied to the selected quantity of plates for at least one duty cycle. Next, the actual amperage and the actual temperature of the hydrogen generating system are measured again, and the process is repeated.

Referring next to FIG. 21, an additional flow chart showing an operation of the electronic controller 202 is shown. At 302, upon an initialization of the processor(s) 204 and other hardware associated with the hydrogen generating system 11, a target amperage (e.g., about 20 amps and about 30 amps), an optimal temperature (e.g., about 160° F.), and a maximum threshold temperature (e.g., 180° F.) are determined/received at 304. In one embodiment, the optimal temperature is a range of temperatures, for example, the optimal temperature may be a temperature between 140° F. and 160° F. After the target amperage, the optimal temperature, and the maximum threshold temperature are determined/received, a voltage is applied to at least some (e.g., a selected quantity) of the plurality of plates in the hydrogen generating system.

Using the amperage sensor (not shown) and the temperature sensor 101, at 306, an actual amperage and an actual temperature of the hydrogen generating system 11 are determined/obtained, and thereafter, compared to the target amperage and the optimal temperature, respectively. At 308, if the actual amperage is below the maximum amperage threshold (e.g., an amperage that does not overburden a battery of the vehicle 19), and if the actual temperature is below the optimal temperature, at 310, full voltage is applied for at least one duty cycle.

At 312, if the actual amperage exceeds the maximum amperage threshold, i.e., the current reaches a level where components may be damaged, and if the actual temperature is below the optimal temperature, at 314, a duty cycle is computed resulting in an increased temperature. As one example, the maximum amperage threshold may be 50 amps. However, at 316, if the actual temperature equals the optimal temperature, at 318, a duty cycle is computed and a rated amount of hydrogen gas is produced.

If however, at 316, the actual temperature exceeds the optimal temperature, at 320, a duty cycle is reduced to maintain the temperature. After the duty cycle is reduced, the actual amperage is compared to the maximum safe amperage. If, at 322, the actual amperage is less than or equal to a maximum safe amperage threshold, the actual temperature is compared to the maximum threshold temperature. At 328, if the actual temperature exceeds the maximum temperature threshold, at 330, a current of the hydrogen generating system 11 is turned off, an actual temperature (e.g., a second actual temperature) is measured, and the current of the hydrogen generating system 11 is turned on when it is determined that the second actual temperature is below the maximum temperature threshold.

If however, at 322, after the duty cycle has been reduced and the actual amperage exceeds a maximum safe amperage threshold (to prevent damage to the system), at 324, the current of the hydrogen generating system 11 is turned off for a predefined period of time (e.g., three minutes). At 326, after the predefined period of time, the current is turned back on. Thereafter, an actual amperage (e.g., a second actual amperage) is determined and compared to the maximum safe amperage, and the process is repeated.

In addition to the above advantages, using interchangeable electrode plates as anodes and cathodes also maximizes gas production by optimizing the quantity of energized (e.g., active) electrode plates based on a target amperage. As more electrode plates are energized, the quantity of electrolyte to electrode plate transitions is increased which increases the gas production per amp.

A transition occurs where electricity passes from the liquid electrolyte to the metal of an electrode plate (the electrolyte/plate interface). Hydrogen gas is formed at this electrolyte/plate interface. Hence, if an electric current makes the same amount of hydrogen gas for each transition from liquid to metal, the more times a current is forced to make the transition, the more hydrogen gas is produced per amp and the more efficient the hydrogen generating system becomes.

For example, when anodes 514 and 516 in the embodiment shown in FIG. 23 are energized, the electrolyte increases in temperature, becomes more conductive, and the current increases. When the current reaches 30 amps, anodes 512 and 516 are energized. The current now drops because the additional transitions limit the current. This process continues as anodes 512 and 518, then anodes 510 and 518, and then anodes 510 and 520 are sequentially energized. After anodes 510 and 520 have been energized, individual anodes are energized, starting with anode 514 followed in turn by anode 516, anode 512, anode 518, anode 510, and finally anode 520. In practice, it is not necessary to perform all the steps just described. Some steps may not be reached while others may be skipped. As further described below, any single anode, as opposed to multiple anodes, may be selected to be energized based, for example, on amperage and/or temperature. The electrolyte concentration is set to allow sufficient current to flow at the largest plate set contemplated to produce the desired gas. As explained above, when an amperage threshold is detected, additional plates may be energized to enable the hydrogen generating system 11 operate at optimal production. The conversion to an optimal operating electrode plate configuration is a factor in the increased efficiency of the electrolysis process.

Further, as a temperature of an aqueous solution increases, an amperage of the hydrogen generating system 11 also increases. Therefore, with 200 mL of electrolytic solution using multiple anodes and cathodes, an actual amperage may become excessive. The methods of controlling and/or limiting the actual amperage while allowing a use of multiple anodes and cathodes described above enable a use of the multiple anodes and cathodes to provide constant amperage from a start-up of the electrolytic generating system 11 until it is turned off.

Although described in connection with an exemplary computing system environment, embodiments of the disclosure are operational with numerous other general purpose or special purpose computing system environments or configurations. Examples of well known computing systems, environments, and/or configurations that may be suitable for use with aspects of the disclosure include, but are not limited to, mobile computing devices, personal computers, server computers, hand-held or laptop devices, multiprocessor systems, microprocessor-based systems, programmable consumer electronics, mobile telephones, network PCs, minicomputers, mainframe computers, distributed computing environments that include any of the above systems or devices, and the like.

A method for dynamically adding or removing a quantity of active electrode plates based on actual amperage will now be described with reference to FIGS. 22-28.

FIG. 22 is a flow chart showing an operation of the electronic controller 202 dynamically adding or removing a quantity of active electrode plates from an electrode plate assembly (e.g., electrode plate assembly 502 in FIG. 23) based on at least one of an actual amperage and an actual temperature.

At 402, upon receiving a minimum amperage threshold, a maximum amperage threshold, a maximum temperature threshold, and an actual temperature (e.g., first actual temperature of the hydrogen generating system 11), at 404, the electronic controller 202 selects a first plurality of plates (e.g., an initial plurality of plates) from the electrode plate assembly 502. The selection of the first plurality of plates is based on at least one of the following: the minimum amperage threshold, the maximum amperage threshold, and the first actual temperature of a hydrogen generating system. The first actual temperature may be the temperature of the hydrogen generating system 11 upon start-up. After the first plurality of plates is selected, at 406, a voltage is applied to the first plurality of plates.

After the voltage is applied to the first plurality of plates, at 408, an actual amperage (e.g., a first actual amperage) and an actual temperature (e.g., a second actual temperature) of the hydrogen generating system 11 is determined. At 410, the first actual amperage is compared to the minimum amperage threshold and the maximum amperage threshold. At 412, if it is determined, based on the comparison, that the first actual amperage is between the minimum amperage threshold and the maximum amperage threshold, at 414, a voltage is again applied to the first plurality of electrode plates. If however, at 412, it is determined that the first actual amperage is not between the minimum amperage threshold and the maximum amperage threshold, and, at 416, the first actual amperage is greater than or equal to the maximum amperage threshold, at 418, a second plurality of electrode plates is selected from the electrode plate assembly 502 whereafter a voltage is applied to the second plurality of electrode plates.

If however, at 412, it is determined that the first actual amperage is not between the minimum amperage threshold and the maximum amperage threshold, and, at 416, the first actual amperage is not greater than or equal to the maximum amperage threshold, at 420, it is determined if the first actual amperage is less than or equal to the minimum amperage threshold. If, at 420, the first actual amperage is less than or equal to the minimum amperage threshold, the second plurality of plates selected includes more plates than the first plurality of plates. However, if the second actual amperage is equal to the minimum amperage threshold or if the second actual amperage is below the minimum amperage threshold, at 422, a second plurality of electrode plates that includes fewer plates than the first plurality of plates is selected from the electrode plate assembly 502.

FIG. 23 is a further example of an electrode plate assembly (e.g., the electrode plate assembly 502 described above). The electrode plate assembly 502 can be used in place of the assembly shown above in FIGS. 6-8 in a housing, such as housing 13′, sized accordingly.

The electrode plate assembly 502 includes two cells (e.g., cell 504 and cell 506) that share a common cathode 506. The present disclosure enables the cells 504 and 506 to operate (or run) in parallel to achieve a sufficient amount of hydrogen gas production (e.g., about 2 liters of hydrogen gas per minute) at low temperatures (e.g., about 40° F.). The cell 504 includes 11 electrode plates, three of which are anodes (e.g., anode 510, anode 512, and anode 514) and one of which is the cathode 508. The cell 506 includes 12 electrode plates, three of which are anodes (e.g., anode 516, anode 518, and anode 520) and one of which is the cathode 508. By providing two cells that are asymmetrical (cell 504 including 11 electrode plates, and the cell 506 including 12 electrode plates), increased control and increased resolution is obtained. That is, with the cells operating in parallel, the electronic controller 202 is able to increase and decrease a quantity of active electrode plates in smaller amounts, described below.

In this embodiment, a distance between each electrode plate in the electrode plate assembly 502 is suitably about 3 mm, and a thickness of each electrode plate is suitably about 20 gauge. One of ordinary skill in the art will appreciate that a quantity of electrode plates, a distance between each electrode plate, and a thickness of each electrode plate are merely exemplary and are not intended to limit the scope of the present disclosure.

The electrode plate assembly 502 is configured to have a voltage applied to a quantity of electrode plates less than the total quantity of electrode plates in each cell 504 and 506. To achieve this, the total quantity of electrode plates (e.g., 22 plates with the cells 504 and 506 operating in parallel) are separated into electrode plate sets (e.g., electrode plate set 1, electrode plate set 2, electrode plate set 3, electrode plate set 4, and electrode plate set 5). Each electrode plate set has a different quantity of electrode plates. In this embodiment, a quantity of electrode plates in each electrode plate set increases from electrode plate set 1 to electrode plate set 5. For example, electrode plate set 1 includes 14 electrode plates, electrode plate set 2 includes electrode 16 plates, electrode plate set 3 includes 18 electrode plates, electrode plate set 4 includes 20 electrode plates, and electrode plate set 5 includes 22 electrode plates. Each of the electrode plate sets are defined by anode plates at opposing ends of each electrode plate set. For example, electrode plate set 1 has anode 514 and anode 516 at opposing ends, electrode plate set 2 has anode 512 and anode 516 at opposing ends, electrode plate set 3 has anode 512 and anode 518 at opposing ends, electrode plate set 4 has anode 510 and anode 518 at opposing ends, and electrode plate set 5 has anode 510 and anode 520 at opposing ends.

FIG. 24 is a graph that includes data that further illustrates how the electronic controller 202 determines which electrode plate set is active (e.g., which electrode plate set receives a voltage). In this embodiment, the determination is based on a target amperage, and more specifically, a target amperage range bound by a minimum amperage threshold and maximum amperage threshold. In this example, the minimum amperage threshold is 20 amps and the maximum amperage threshold is 30 amps. The minimum amperage threshold and the maximum amperage threshold may be automatically set and/or manually selected by a user via the display device. Furthermore, the minimum amperage threshold of 20 amps and the maximum amperage threshold of 30 amps are merely exemplary are not intended to limit the scope of the present disclosure.

Generally speaking, at any given temperature, amperage decreases as a quantity of active electrode plates increase. In addition, at any given quantity of active electrode plates, amperage increases as temperature increases. Based on this understanding, at a given temperature, applying a voltage to an electrode plate set with a lesser quantity of electrode plates will return a higher amperage compared to applying a voltage to an electrode plate set with a greater quantity of electrode plates at the same temperature. Therefore, when a voltage is applied to a particular electrode plate set and an actual amperage reaches the maximum amperage threshold, the electronic controller 202 activates an electrode plate set that has a greater quantity of electrode plates than the presently active electrode plate set, thereby decreasing the amperage. In contrast, when a voltage is applied to a particular electrode plate set, and an actual amperage reaches the minimum amperage threshold, the electronic controller 202 activates an electrode plate set that has a lesser quantity of electrode plates than the presently active electrode plate set, thereby increasing the amperage.

Thus, at a given temperature, applying a voltage to an electrode plate set that includes the least quantity of electrode plates (e.g., plate set 1 if the cells 504 and 506 are operating in parallel) returns the highest amperage. Therefore, in the example shown in FIG. 24, because the temperature of the hydrogen generating system 11 is only at 60° F., the electronic controller 202 initially activates electrode plate set 1, which returns an actual amperage of 34.8 amps. However, 34.8 amps is above the maximum amperage threshold of 30 amps. Therefore, the electronic controller 202 increases a quantity of active electrode plates by activating electrode plate set 2. Activating electrode plate set 2 returns an actual amperage of 30.5 amps. However, 30.5 amps is still above the maximum amperage threshold of 30 amps. Therefore, the electronic controller 202 increases a quantity of active electrode plates by activating electrode plate set 3. Activating electrode plate set 3 returns an actual amperage of 28 amps.

As shown in FIG. 24, the temperature of the hydrogen generating system increases with time. As mentioned above, as the temperature of the hydrogen generating system 11 increases, amperage increases. Therefore, while the electrode plate set 3 initially returns an actual amperage of 28 amps, as time elapses, the temperature of the hydrogen generating system 11 increases from 69° F. to 78° F. However, once the temperature of the hydrogen generating system 11 reaches 78° F., the electrode plate set 3 returns an actual amperage of 30.30 amps, which is above the maximum amperage threshold of 30 amps. Therefore, the electronic controller 202 increases a quantity of active electrode plates by activating electrode plate set 4, and at 78° F., the electrode plate set 4 returns an actual amperage of 23.7 amps. Once the temperature of the hydrogen generating system 11 reaches 118° F., the electrode plate set 4 returns an actual amperage of 31.50 amps, which is above the maximum amperage threshold of 30 amps. Therefore, the electronic controller 202 increases a quantity of active electrode plates by activating electrode plate set 5, and at 118° F., the electrode plate set 5 returns an actual amperage of 26.2 amps.

As mentioned above, using two cells (e.g., cells 504 and 506) that are asymmetrical increases control and resolution. For example, once the hydrogen generating system 11 reaches an optimal temperature, the electronic controller 202 may stop operating each of the cells 504 and 506 in parallel. In this embodiment, operating only one cell, three electrode plate sets are left available:

(1) electrode plate set 6, which is in the cell 506, and includes all of the electrode plates from anode 518 to the cathode 508, totaling 10 electrode plates;

(2) electrode plate set 7, which is in the cell 504, and includes all of the electrode plates from anode 510 to the cathode 508, totaling 11 electrode plates; and

(3) electrode plate set 8, which is in the cell 506 and includes all of the electrode plates from anode 520 to the cathode 508, totaling 12 electrode plates.

Thus, because the cell 506 has one more electrode plate than the cell 504 (making the two cells asymmetrical), electrode plate sets 6, 7, and 8 increase in total electrode plates by only 1 electrode plate, increasing the control and resolution.

In addition to adding and removing a quantity of active electrode plates to maintain an amperage between a minimum amperage threshold and maximum amperage threshold, if a temperature of the hydrogen generating system 11 exceeds a maximum temperature threshold, the electronic controller 202 may also adjust the duty cycle.

FIG. 25 is a graph that illustrates gas production versus time. The graph represents the results achieved by implementing what is shown in FIG. 22, where the electronic controller 202 dynamically added/removed a quantity of electrode plates and/or at least one of the applied voltage and a duty cycle based on amperage and temperature. As shown in the graph, about 2.8 liters of hydrogen gas are produced per minute upon initial start-up. The last two points on the graph (points 602 and 604) represent where a current was limited in order to prevent an increase in temperature.

FIG. 26 is a graph that illustrates temperature versus time. As expected, the temperature rises faster in the beginning when fewer electrode plates are active, and as more electrode plates are added, the rate of increase in the temperature is reduced.

FIG. 27 is a graph that illustrates current/amperage versus time. As shown in the graph, the actual amperage decreases with time because, as time elapses, temperature increases and a quantity of active electrode plates operated is increased to decrease the amperage (see FIG. 22). Further, power dissipated is equal to a voltage applied across a cell multiplied by the amps passing through the cell. As amperage drops at higher temperatures, the power flowing to the hydrogen generating system 11 drops and a rate of temperature rise slows down.

FIG. 28 is a graph that illustrates efficiency versus time, where efficiency is an amount of hydrogen gas produced per amperage of electricity. As shown in the graph, efficiency generally improves as temperature increases and the quantity of active electrode plates increases.

With reference back to FIG. 27, as shown in the graph, the actual amperage decreases with time. The efficiency achieved in each plate set is as follows: electrode plate set 1 (0.083), electrode plate set 2 (0.092), electrode plate set 3 (0.094), electrode plate set 4 (0.104), and electrode plate set 5 (0.110). As shown here, increasing a quantity of active electrode plates between an anode and a cathode increases efficiency.

FIG. 29 is a graph that illustrates gas production versus temperature. As shown in the graph, about 2.7 liters of gas per minute is achievable at 60° F. These numbers are merely exemplary and are not intended to limit the scope of the present disclosure. For example, further tests have shown that 2 liters of hydrogen gas per minute can be achieved at only 40° F., without going over 30 amps.

OPERATING ENVIRONMENT

In one embodiment shown in FIG. 18, the hydrogen generating system 11 is mounted in the vehicle 19, such as a truck, and is mounted outside the engine 21, for example, behind a cab of the truck. Other mounting arrangements are contemplated.

In this embodiment, the hydrogen output from the hydrogen generating system 11 is directed to the engine 21 of the truck. The hydrogen gas is a supplement to the conventional fuel of such an engine (e.g., a petroleum-based fuel or “fossil fuel” such as unleaded gasoline, diesel, natural gas or propane). The hydrogen gas can improve fuel efficiency of the engine 21. The hydrogen gas may enable the engine 21 to meet stringent emission standards while also increasing fuel economy and/or power output.

EXAMPLE SURFACE AREA INCREASE DUE TO HOLES IN THE PLATE

Plate Parameters

Hole radius=0.00117 meters

Length of plate=0.40005 meters

Width of plate=0.17780 meters

Thickness of plate=16 gauge=0.00160 meters

Number of holes=200

Surface Area of Plate with No Holes

Top & Bottom

0.40005 meters×0.17780 meters=2.80035 meters² (L×W)

2.80035×2=5.6007 meters²(top and bottom)

Sides

0.00160 meters×0.17780 meters×2=0.02235 meters² (short sides)

0.00160 meters×0.40005 meters×2=0.05029 meters² (long sides)

Total Surface Area of Plate

5.6007 meters²+0.02235 meters²+0.05029 meters²=5.67258 meters²

Surface Area Removed from Holes being Added

200×pi×r²×2=200×0.07976×0.00117×0.00117×2=0.06756 in²

Surface Area Gained from Cylinders being formed at Each Hole Made

200{(2×pi×r×r)+(2×pi×r×h)−(2×pi×r×r)} Note accounts for the top/bottom circles removed.

200{(2×0.07976 meters×0.00117 meters×0.00117 meters)+(2×0.07976 meters×0.00117 meters×0.00160 meters)−(2×0.07976 meters×0.00117 meters×0.00117 meters)}=200×(2×0.07976 meters×0.00117 meters×0.00160 meters)=0.09446 meters²

Surface Area of Plates with Holes

Surface Area of Plates with Holes={Surface area of Solid Plate−Surface area of plate removed to form holes +Surface Area Gained from Formation of Cylinders where holes are made}

Surface Area of Plates with Holes=(5.67258 meters²−0.06756 meters²+0.09627 meters²)=5.69620 meters²

Ratio of Surface Area of Plates with Holes vs. Solid Plate-16 Gauge

Plate with Holes/Solid Plate=5.69620/5.67258=0.02553 or 0.51% more surface area

When introducing elements of the present invention or the embodiment(s) thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including” and “having” are intended to be inclusive and mean that there may be additional elements other than the listed elements.

As various changes could be made in the above constructions without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawing[s] shall be interpreted as illustrative and not in a limiting sense. 

1. A hydrogen generating system comprising: a housing defining an interior chamber; an electrolyte solution contained within the interior chamber of the housing; an electrode plate assembly disposed in the interior chamber of the housing and at least in part submerged in the electrolyte solution, the electrode plate assembly comprising: a cathode plate, an anode plate separate from the cathode plate and disposed in spaced relationship therewith, and at least one neutral plate separate from both the anode plate and the cathode plate and disposed therebetween in spaced relationship with the anode plate and the cathode plate; and a power source in electrical communication with the electrode plate assembly.
 2. The hydrogen generating system of claim 1 wherein the anode plate is a first anode plate, the electrode plate assembly further comprising: a second anode plate separate from the first anode plate and in spaced relationship therewith with the first anode plate being disposed intermediate the cathode plate and the second anode plate; and at least one additional neutral plate separate from the first anode plate and the second anode plate and being disposed therebetween in spaced relationship with the first and second anode plates.
 3. The hydrogen generating system of claim 2 wherein the electrode plate assembly further comprises: a third anode plate separate from the first and second anode plates and in spaced relationship therewith with the second anode plate disposed intermediate the first anode plate and the third anode plate; and at least one additional neutral plate separate from the anode plates and being disposed between the second anode plate and the third anode.
 4. The hydrogen generating system of claim 1 wherein the anode plate is a first anode plate, the electrode plate assembly further comprising: a second anode plate separate from the cathode plate and disposed in spaced relationship therewith with the cathode plate intermediate the first and second anode plates, and at least one additional neutral plate separate from the first and second anode plates and the cathode plate, and disposed between and in spaced relationship with the second anode plate and the cathode plate
 5. The hydrogen generating system of claim 1 wherein at least three neutral plates are disposed in spaced relationship with each other intermediate the cathode plate and the anode plate.
 6. The hydrogen generating system of claim 2 wherein the first anode plate is configurable between an anode plate and a neutral plate such that each plate disposed between the second anode plate and the cathode plate acts in the manner of a neutral plate.
 7. The hydrogen generating system of claim 1 further comprising a heater operable to heat the interior chamber of the housing to decrease the time required for the electrolytic solution to reach an operating temperature.
 8. The hydrogen generating system of claim 7 wherein the heater is disposed exterior of the housing in abutting relationship therewith.
 9. The hydrogen generating system of claim 1 wherein the system is operable to deliver hydrogen to a combustion engine, the generating system further comprising a delivery system for delivering hydrogen from the generating system to the engine, the delivery system including a condenser for inhibiting water vapor from entering the engine.
 10. The hydrogen generating system of claim 9 wherein the condenser is a bubbler-type condenser.
 11. The hydrogen generating system of claim 1 further comprising a reservoir holding maintenance solution, the reservoir being in fluid communication with the interior chamber to deliver maintenance solution to the interior chamber.
 12. The hydrogen generating system of claim 11 wherein the reservoir is disposed above the chamber for gravity flow of the maintenance solution to the chamber.
 13. The hydrogen generating system of claim 11 wherein the maintenance solution includes distilled water and at least one buffer solution.
 14. The hydrogen generating system of claim 1 wherein the cathode plate is a first cathode plate, the electrode plate assembly further comprising: a second cathode plate separate from the first cathode plate and in spaced relationship therewith, the anode plate being separate from the first and second cathode plates and disposed intermediate said cathode plates in spaced relationship therewith; at least one neutral plate disposed between the anode plate and the first cathode plate in spaced relationship with said anode plate and said first cathode plate; and at least one additional neutral plate disposed between the anode plate and the second cathode plate in spaced relationship with said anode plate and said second cathode plate.
 15. A hydrogen generating system comprising: a housing defining an interior chamber; an electrolyte solution contained within the interior chamber of the housing; an electrode plate assembly disposed in the interior chamber of the housing and at least in part submerged in the electrolyte solution, the electrode plate assembly comprising: a plurality of electrode plates, at least one electrode plate having opposite faces exposed to the electrolyte solution, and a cathode plate having opposite faces exposed to the electrolyte solution, said at least one electrode plate having a length, a height, a thickness and a plurality of surface features on at least one of the opposite faces such that the at least one electrode plate has a surface area that is greater than a surface area of a hypothetical electrode plate having the same length, height and thickness as the at least one electrode plate and free from said surface features; and a power source in electrical communication with the electrode plate assembly.
 18. The hydrogen generating system of claim 17 wherein the surface features comprise at least one of projections extending outward from at least one of the opposite faces, impressions disposed in at least one of the opposite faces and holes extending through the thickness of the electrode plate from one of said faces to the other one of said faces.
 19. The hydrogen generating system of claim 18 wherein the electrode plate assembly comprises an anode plate and a cathode plate, the cathode plate being free from surface features.
 20. The hydrogen generating system of claim 18 further comprising a neutral plate separate from and intermediate the anode and cathode plates in spaced relationship therewith, at least the neutral plate having said features.
 21. The hydrogen generating system of claim 18 wherein the holes comprise slots.
 22. The hydrogen generating system of claim 18 wherein the surface area of each plate having holes is at least about 0.3% greater than the hypothetical plate without such holes.
 23. The hydrogen generating system of claim 18 wherein the surface area of each plate having holes is at least about 0.5% greater than a plate without such holes.
 24. A hydrogen generating system comprising: a housing defining an interior chamber; an electrolyte solution contained within the interior chamber of the housing; an electrode plate assembly disposed in the interior chamber of the housing and submerged at least in part in the electrolyte solution, the electrode plate assembly comprising: a plurality of electrode plates, at least one electrode plate having opposite faces exposed to the electrolyte solution, and a cathode plate having opposite faces exposed to the electrolyte solution, said at least one electrode plate having a length, a height, a thickness and a plurality of holes extending through the thickness of the electrode plate from one of said opposite faces to the other one of said opposite faces; and a power source in electrical communication with the electrode plate assembly.
 25. The hydrogen generator of claim 24 wherein the holes comprise slots.
 26. The hydrogen generator of claim 24 wherein the surface area of each plate having holes is at least about 0.3% greater than a plate without such holes.
 27. The hydrogen generator of claim 24 wherein the surface area of each plate having holes is at least about 0.5% greater than a plate without such holes.
 28. An electrode plate assembly for a hydrogen generator comprising: a plurality of electrode plates; at least one electrically non-conductive bracket engaging the plates, the bracket comprising a bridge and a plurality of spacers extending from the bridge in spaced relationship with each other, the spacing between said spacers being adapted for receiving a respective one of the electrode plates therebetween such that the plates are maintained by the spacers in uniform spaced relationship with each other.
 29. The plate assembly of claim 28 wherein the plate assembly comprises a plurality of said electrically non-conductive brackets disposed about a perimeter of said plates.
 30. The plate assembly of claim 28 wherein at least some of the plates have a plurality of holes to increase the surface area exposed to the electrolyte solution.
 31. The plate assembly of claim 28 wherein the plurality of plates includes at least 6 plates having a plurality of holes therein to increase the surface area exposed to the electrolytic solution.
 32. The plate assembly of claim 29 wherein the holes are slots.
 33. The plate assembly of claim 30 wherein the plurality of plates includes two end plates having substantially no holes therein.
 34. The plate assembly of claim 28 including at least three of said brackets and further comprising fasteners for securing the brackets and plates together.
 35. The plate assembly of claim 31 wherein the plurality of plates comprises a pair of end plates having substantially no holes therein. 